Packaging and Sealing Apparatus and Method

ABSTRACT

A packaging and sealing apparatus and method may package and seal a product. The apparatus and method may provide a greater efficiency for packaging and sealing a product. The rate capacity or quantity of sealed product packages may be up to approximately 50 packages per minute. The apparatus may create packaged product during continuous conveying of the product for increased apparatus packaging capacity. The apparatus may create packaged product using coupled variable-length conveyors to move the sealing system with the conveyed product being packaged through a fixed-length apparatus. The apparatus and method may not require a footprint or space greater than conventional food packaging equipment. The package seals created with the apparatus may provide an improved seal and reduce or eliminate premature spoilage of the product.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims the benefit of U.S. Provisional Application No. 62/718,785 filed Aug. 14, 2018, which is incorporated by reference in its entirety.

TECHNICAL FIELD

The disclosure relates generally to a packaging and sealing apparatus and method. In particular, the disclosure relates to a bulk packaging and sealing apparatus and method that may improve food packaging and sealing efficiency.

BACKGROUND

Standard packaging and sealing equipment can require substantial space in manufacturing and production facilities. Standard equipment can also require a rate of sealing and separating per minute to package a product, such as buns, that may not provide the best efficiency.

SUMMARY

Embodiments of the present disclosure generally provide a packaging and sealing apparatus that may include two variable-length conveyors that may be provided to transport a product. The apparatus may further provide at least one traveling sealing bar that may seal the product in a packaging while the product is being conveyed. A mechanical drive system may be arranged below the packaging and sealing apparatus to control movement of the at least one traveling sealing bar and the two variable-length conveyors. The two variable-length conveyors may be coupled and may provide a constant overall apparatus length. An open frame may be arranged to provide access to the packaging and sealing apparatus. A force-sensitive drive linkage may be arranged proximate to at least one sealing bar. A slicer may be provided to separate sealed product packages at a rate of up to approximately 50 packages per minute. A plurality of sealing bars and wheels may be provided to seal the product in the packaging according to user needs, and sealing may be provided across a width of the packaging and at various center positions of the packaging according to a product size, user-required product grouping, or a combination of the product size and the user-required product groupings. The two variable-length conveyors may provide a fixed overall apparatus length that may allow the sealing to occur while the product is conveyed during constant motion. The packaging and sealing apparatus may provide real-time feedback to a user or an operator.

A method of packaging and sealing a product may provide the steps of accumulating a product for processing, grouping the product into a quantity and an arrangement desired by a user, and slicing the product as desired by the user. Additionally, the method may provide the steps of finalizing a product grouping for packaging, wrapping the packaging around the product grouping, sealing the product into the packaging, and conveying a product packaging into at least one transport container and transporting to the at least one transport container to a storage location for shipping. The method of packaging and sealing a product may include the step of separating the product packaging as desired by the user. The method of packaging and sealing a product may include the step of sealing the product in the packaging which may be performed while the product is being continuously transported by the two variable-length conveyors within a fixed overall length of the apparatus. Transporting the product by two variable-length conveyors may allow package sealing around the product to be completed while the product undergoes a constant conveying motion that may increase apparatus packaging capacity while maintaining an overall fixed apparatus length. The method may provide the step of providing real-time feedback to a user or an operator. The method may provide coupling the two variable-length conveyors. The method may provide the step of separating the product packages at a rate of up to approximately 50 packages per minute.

Other technical features may be readily apparent to one skilled in the art from the following drawings, descriptions and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of this disclosure and its features, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:

FIG. 1A is a top view of a packing and sealing apparatus according to an embodiment of the present disclosure;

FIG. 1B is a side view of a packing and sealing apparatus according to an embodiment of the present disclosure;

FIG. 1C is a front view of a packing and sealing apparatus according to an embodiment of the present disclosure;

FIG. 1D is a perspective view of a packing and sealing apparatus according to an embodiment of the present disclosure;

FIG. 2 is a view of two coupled variable-length conveyors with a fixed overall length through the entire operation of a cross-sealing bar apparatus according to an embodiment of the present disclosure;

FIG. 3 is a view of a mechanical drive system according to an embodiment of the present disclosure to control the motion of the two variable-length conveyors;

FIG. 4 is a perspective side view of a frame for a packing and sealing apparatus according to an embodiment of the present disclosure; and

FIG. 5 is a perspective side view of sealing bars for a packing and sealing apparatus according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

Embodiments of the present disclosure generally may provide a packaging and sealing apparatus and method. The apparatus and method may improve manufacturing efficiency by increasing the quantity of sealed packages per minute while reducing an equipment footprint for handling similar product volume with conventional packaging apparatuses.

FIGS. 1A-1D depict packaging and sealing apparatus 100A-100D according to an embodiment of the present disclosure. Packaging and sealing apparatus 100A-100D may take raw material and peel or seal around a product, as the product travels through packaging and sealing apparatus 100A-100D. As the product travels through packaging and sealing apparatus 100A-100D, a bag may be created that may be formed to contain the product. It should be appreciated that a moving process or method to create the bag to receive the product may provide a more efficient system that may remain in motion while sealing the product in packaging, such as a bag, that may yield higher packaging rates compared to conventional sealing equipment. For example, a footprint of packaging and sealing apparatus 100A-100D may be equivalent to the same dimensions or footprint of conventional sealing equipment. Thus, packaging and sealing apparatus 100A-100D may have backwards compatibility and may prevent equipment or the space housing the equipment from having to be reconfigured to increase a volume of product being processed and/or sealed.

Packaging and sealing apparatus 100A-100D may provide an increased quantity of packaged product compared to conventional food production or sealing equipment. Conventional food production or sealing equipment may provide approximately 30 packages per minute compared to approximately 50 packages per minute that may be provided by packaging and sealing apparatus 100A-100D in embodiments of the present disclosure. It should be appreciated that rates of approximately 30 packages per minute may be achieved in packaging of standard 4-inch hamburger buns or buns for ¼ lb. hamburgers using conventional packaging equipment, which may be further increased to approximately 50 packages per minute using sealing apparatus 100A-100D in embodiments of the present disclosure. It should also be appreciated that rate may change depending on the type of products being packaged, including, but not limited to, hot dog buns, biscuits, and additional products without departing from the present disclosure. It should further be appreciated that the quantity of packages per minute also may vary depending on a size of a product undergoing packaging and sealing. It should be appreciated that packaging and sealing apparatus 100A-100D may provide more than approximately 50 packages per minute without departing from the present disclosure. It should be appreciated that a maximum number of packages per minute may be approximately 50 packages in embodiments of the present disclosure; however, fewer packages per minute may be provided without departing from the present disclosure. It should also be appreciated that packaging and sealing apparatus 100A-100D may provide approximately up to twice the number of packages per minute compared to conventional food production or sealing equipment in embodiments of the present disclosure.

Real-time feedback may be provided by packaging and sealing apparatus 100A-100D according to an embodiment of the present disclosure. Real-time feedback may communicate information including, but not limited to, speed data, temperature data, humidity data, environmental data, pressure data, alerts to the operator, and additional types of data and alerts. Additionally, real-time feedback may be provided to alert the operator or user regarding whether an appropriate quantity of pressure required to effectively seal a product has been satisfied. It should be appreciated that real-time feedback may alert the operator or user when sealing bars and wheels should be replaced or repaired. However, other types of real-time feedback may be provided without departing from the present disclosure.

FIG. 2 depicts variable-length conveyors 200 according to embodiments of the present disclosure. Variable-length conveyors 200 may be two variable-length conveyors that may be coupled together for a fixed overall length system. Variable-length conveyors 200 may be constructed in manner that does not include holes or openings for the product and other items to inadvertently fall through during the process of packaging and sealing while being conveyed through the apparatus 100A-100D.

FIG. 3 depicts mechanical or servo drive 300 according to embodiments of the present disclosure. Mechanical or servo drive 300 may be provided below packaging and sealing apparatus 100A-100D. Mechanical or servo drive 300 may enable or provide communication of packaging and sealing apparatus 100A-100D performance, including additional sealing information from force-sensitive drive linkage 520 (FIG. 5) operation.

FIG. 4 depicts dynamic cross-sealing of packaging and sealing apparatus 400, including servo-driven seal bar motion 410 and open frame 420, according to embodiments of the present disclosure. Servo-driven seal bar motion 410 may be from left to right or from right to left in embodiments of the present disclosure. Open frame 420 may provide dynamic system access to components found in packaging and sealing apparatus 400. Dynamic sealing of the packaging may be completed within the operational range of the coupled variable-length conveyors.

FIG. 5 depicts force-sensitive cross-sealing system 500 according to embodiments of the present disclosure. At least one sealing bar 510 may be provided that may have a quick release and may be more efficiently replaced or repaired than other sealing mechanisms that have been previously used. At least one sealing bar 510 may provide an improved cross-seal quality and may cause film to melt together to seal product. At least one sealing bar 510 may effectively seal product and may protect against spoilage. It should be appreciated that a plurality of sealing bars may be utilized without departing from the present disclosure. At least one sealing bar 510 may be quick-swap heat sealing bars. Force-sensitive drive linkage 520 may be provided proximate at least one sealing bar and may communicate with at least one sealing bar 510.

It should be appreciated that product may begin to be sealed across a width of a package of product according to embodiments of the present disclosure. It should be appreciated that sealing the product across the width of the package may be rate-limiting. Packages of product may be sealed by splitting the packages across the center. For example, a package of 24 hamburger buns may be sealed and provide 12 hamburger buns in a first sealed portion and 12 hamburger buns in a second sealed portion. Packages of product may also be sealed by providing a tri-seal across packages. For example, 24 hamburger buns may be sealed and provide 8 hamburger buns in a first sealed portion, 8 hamburger buns in a second sealed portion, and 8 hamburger buns in a third sealed portion. Packages of product may be completely sealed after sealing sides of the packages.

It should be appreciated that a product may follow a production process and may be sealed prior to being transported by a conveyor according to embodiments of the present disclosure. A production process may include accumulating product by utilizing an accumulator. The process may provide grouping the product into a desired number of sections prior to packaging. Further, the process may provide slicing the product as required by the user. After the product is sliced, the process may provide regrouping the product into a desired pattern prior to packaging. The packaging process may include sealing the product into packages using sealing bars and wheels. After the product is sealed, a conveyor may transport the sealed product to a basket or container and may be stacked. The basket or container may be transported to a desired facility or location. It should be appreciated that basket or container conveyance may occur underneath packaging and sealing apparatus 100A-100D (FIGS. 1A-1D) and may consolidate space required to transport the product. It should also be appreciated that packaging and sealing apparatus 100A-100D (FIGS. 1A-1D) may be in conformance with sanitary or food production design requirements.

It should be appreciated that the packaging and sealing apparatus may be retrofit into other applications and/or equipment according to embodiments of the present disclosure. It should be appreciated that the packaging and sealing apparatus may provide the advantage of a faster system that may more efficiently seal product compared to conventional equipment as the present disclosure sealing process is conducted during constant conveyed motion. It should further be appreciated that packaging and sealing apparatus may be sized depending on the application and may be utilized to seal product in bulk quantities in embodiments of the present disclosure. Bulk quantities may include packaging and sealing thousands of items per minute. For example, the packaging and sealing apparatus may be utilized to produce buns and biscuits for production use at a fast-food restaurant chain. It should be appreciated that product may still be further processed after being packaged and sealed.

It should be appreciated that the packaging and sealing apparatus may allow for product to flow from left to right according to embodiments of the present disclosure; however, it may flow in a different direction without departing from the present disclosure. It should also be appreciated that the packaging and sealing apparatus may provide valves for air systems and a control panel that may provide real-time feedback.

It may be advantageous to set forth definitions of certain words and phrases used in this patent document. The terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation. The term “or” is inclusive, meaning and/or. The phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like.

While this disclosure has described certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure, as defined by the following claims. 

What is claimed is:
 1. A packaging and sealing apparatus, comprising: two variable-length conveyors provided to transport a product; at least one traveling sealing bar provided to seal the product in a packaging while the product is being conveyed; and a mechanical drive arranged below the one traveling sealing bar and the two variable-length conveyors to control movement of the at least one traveling sealing bar and the two variable-length conveyors.
 2. The apparatus of claim 1, wherein the two variable-length conveyors are coupled and provide a constant overall apparatus length.
 3. The apparatus of claim 1 further comprising: an open frame arranged to provide access to the packaging and sealing apparatus.
 4. The apparatus of claim 1 wherein the at least one traveling sealing bar melts the packaging to create bags.
 5. The apparatus of claim 1 further comprising: a force-sensitive drive linkage arranged proximate the at least one traveling sealing bar.
 6. The apparatus of claim 1 further comprising: a slicer provided to separate sealed product packages at a rate of up to approximately 50 packages per minute.
 7. The apparatus of claim 1 further comprising: a plurality of sealing bars and wheels provided to seal the product in the packaging according to user needs.
 8. The apparatus of claim 1, wherein sealing is provided across a width or the packaging and at various center positions of the packaging according to a product size, user-required product groupings, or a combination of the product size and the user-required product groupings.
 9. The apparatus of claim 1, wherein the two variable-length conveyors provide a fixed overall apparatus length to allow sealing to occur while the product is conveyed during constant motion.
 10. The apparatus of claim 1, wherein the packaging and sealing apparatus provides real-time feedback to a user or an operator.
 11. A method of packaging and sealing a product, comprising: accumulating a product for processing; grouping the product into a quantity and an arrangement desired by a user; slicing the product as desired by the user; finalizing a product grouping for packaging; wrapping packaging around the product grouping; sealing the product grouping into the packaging; conveying the product grouping sealed into the packaging into at least one transport container; and transporting the at least one transport container to a storage location for shipping.
 12. The method of claim 11 further comprising: separating the product packaging as desired by the user.
 13. The method of claim 11, wherein sealing the product grouping in the packaging is performed while the product is being continuously transported by two variable-length conveyors within a fixed length apparatus.
 14. The method of claim 11, wherein transporting the product by two variable-length conveyors allows the sealing step to be completed while the product undergoes a constant conveying motion to increase apparatus packaging capacity while maintaining an overall fixed apparatus length.
 15. The method of claim 13, wherein the two variable-length conveyors are coupled together.
 16. The method of claim 11 further comprising: providing real-time feedback to a user or an operator.
 17. The method of claim 11 further comprising: packaging the product at a rate of up to approximately 50 packages per minute. 